bs 499-2009. welding symbol

raising standards worldwide

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Welding terms and symbols

Part 1: Glossary for welding, brazing and thermal cutting

BS 499-1:2009




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Publishing and copyright informationThe BSI copyright notice displayed in this document indicates when the document was last issued

BSI 2008

ISBN 978 0 580 58471 8

ICS 01.040.25; 25.160.01

The following BSI references relate to the work on this standard:Committee reference WEE/1Draft for comment 08/30162761 DC

Publication historyFirst published August 1933Second edition June 1939Third edition October 1952Fourth edition October 1965Fifth edition November 1983Sixth edition February 1991Seventh edition December 2008

Amendments issued since publication

Date Text affected

BRITISH STANDARDBS 499-1:2009

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Contents

Foreword v

1 Scope 1

Section 1. Terms common to more than one section 2

Section 2. Terms relating to welding with pressure 19Subsection 21. Terms relating to more than one subsection 19Subsection 22. Terms relating only to resistance welding 28Subsection 23. Terms relating only to friction welding 47Subsection 24. Terms relating only to pressure welding 48Subsection 25. Terms relating only to diffusion welding 48Subsection 26. Terms relating only to explosive welding 49Subsection 27. Terms relating only to friction stir welding 49

Section 3. Terms relating to fusion welding (welding withoutpressure) 57Subsection 31. Terms relating to more than one subsection 57Subsection 32. Terms relating only to arc welding 87Subsection 33. Terms relating only to gas welding 98Subsection 34. Terms relating only to electron beam welding 103Subsection 35. Terms relating only to light radiation welding 106Subsection 36. Terms relating only to aluminothermic welding 107Subsection 37. Terms relating only to electro-slag welding 109

Section 4. Terms relating to braze welding and brazing 110Subsection 40. Terms relating only to braze welding 110Subsection 41. Terms relating only to brazing 111

Section 5. Terms relating to testing 113

Section 6. Terms relating to weld imperfections 118

Section 7. Terms relating to cutting 123Subsection 70. Terms relating to more than one subsection 123Subsection 71. Terms relating only to oxygen cutting 126Subsection 72. Terms relating only to arc cutting 128Subsection 73. Terms relating only to spark erosion cutting 128Subsection 74. Terms relating only to electron beam cutting 129Subsection 75. Terms relating only to laser cutting 129

Section 8. Terms relating to health and safety 130

Bibliography 131

Index 133

List of figuresFigure 1 Chart of derivation of welding processes viFigure 2 Chart of derivation of brazing processes viiFigure 3 Chart of derivation of thermal cutting processes viiFigure 4 Root, fusion penetration, weld junction and zones of typicalwelds 3Figure 5 Preparation for square butt weld 7Figure 6 Preparation for butt weld between plates with raisededges 7Figure 7 Preparation for single bevel butt weld with backing 9Figure 8 Configuration for double-covered lap joint 10Figure 9 Configuration for single lapped joint 11Figure 10 Preparation for single V-butt weld 12Figure 11 Oxy-fuel gas pressure welding 20

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Figure 12 Examples of series spot welding 22Figure 13 Forms of projection welds 25Figure 14 Typical example of weld made using pressure Double rowof staggered, spaced spot welds 26Figure 15 Typical example of weld made using pressure Projectionweld 26Figure 16 Foil butt-seam weld 27Figure 17 Weld nugget 28Figure 18 Typical example of weld made using pressure Resistancespot welds 28Figure 19 Typical example of weld made using pressure Seamweld 29Figure 20 Mash weld 29Figure 21 Nail head welding 30Figure 22 Vertical centre electrode 31Figure 23 Vertical offset electrode 31Figure 24 Angle offset electrode 32Figure 25 Cranked offset electrode 32Figure 26 Time and pressure diagram for simple spot, stitch, orprojection welding 35Figure 27 Time and pressure diagram for pulsation spot or projectionwelding 35Figure 28 Time and pressure diagram for spot or projection welding,programme control 36Figure 29 Time and pressure diagram for pulsation spot or projectionwelding, programme control 36Figure 30 Time and pressure diagram for spot welding, programmecontrol with dual-pressure cycle 30Figure 31 Time and pressure diagram for seam welding 30Figure 32 Time and pressure diagram for step-by-step seamwelding 38Figure 33 Time and pressure diagram for roller spot welding 38Figure 34 Time and pressure diagram for step-by-step roller spotwelding 39Figure 35 Time and platen movement diagram for straight flashwelding 39Figure 36 Generalized diagram of speed, applied force, axialmovement and time for continuous drive friction welding 40Figure 37 Generalized diagram of speed, applied force and axialmovement with time for stored energy friction welding 42Figure 38 Angle centre electrode 45Figure 39 Swan-necked electrode 45Figure 40 Basic principle of friction stir welding 50Figure 41 Macrosection of a butt weld showing incompletepenetration 50Figure 42 Heel and heel plunge depth 51Figure 43 Adjustable probe tool 51Figure 44 Fixed bobbin tool 52Figure 45 Self-reacting bobbin tool 52Figure 46 Cross-section of a friction stir weld 54Figure 47 Tool shoulder footprint visible at the exit hole 54Figure 48 Cross-section of friction stir lap weld showing undesirable/extreme plate thinning on the retreating side and a hook feature onthe advancing side of the weld 56Figure 49 Example of back-step sequence 57Figure 50 Sketches of types of joints, types of weld(s) and weldpreparations 58

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Figure 51 Gap, root face, root radius, land, included angle and angleof bevel for typical weld preparations 64Figure 52 Examples of toes, legs, weld widths and fusion faces 66Figure 53 Actual, effective, design and maximum throat thickness oftypical welds 67Figure 54 Examples of excess weld metal 68Figure 55 Welding positions: slope (S) 70Figure 56 Schematic diagram of main welding positions 70Figure 57 Simplified view of main welding positions 71Figure 58 Comparison of UK (USA) and ISO welding positions 71Figure 59 Weld preparation using a fusible insert 73Figure 60 Typical example of butt weld General view of buttweld 75Figure 61 Preparation for double-bevel T-butt welds 76Figure 62 Typical example of multi-run fusion weld Double V-buttweld 77Figure 63 Preparation for fillet weld (T-joint) 77Figure 64 Typical examples of multi-run fusion welds 79Figure 65 Preparation for single U-butt weld 80Figure 66 Typical example of fusion weld Single V-butt weld 81Figure 67 Typical example of fusion weld Fillet weld 82Figure 68 Weave technique 84Figure 69 Example of skip sequence 84Figure 70 Examples of block sequences 85Figure 71 Roots of typical weld preparations 86Figure 72 Penetration bead 86Figure 73 Self-shielded tubular-cored arc welding 92Figure 74 Surge reignition 94Figure 75 Types of rectification 95Figure 76 Neutral oxy-acetylene flame 98Figure 77 Carburizing oxy-acetylene flame 99Figure 78 Carburizing oxy-acetylene flame for a hard surfacingapplication 99Figure 79 Oxidizing oxy-acetylene flame 99Figure 80 Leftward welding 99Figure 81 Rightward welding 99Figure 82 All-position rightward welding 102Figure 83 Diagrammatic representation of a diode gun 104Figure 84 Diagrammatic representation of a triode gun 104Figure 85 Diagrammatic representation of a back-bombardedgun 105Figure 86 Basic equipment for aluminothermic welding 108Figure 87 Electro-slag welding 109Figure 88 Bell butt joint 110Figure 89 Diminishing bell butt joint 110Figure 90 Short bell branch joint 111Figure 91 U-tensile test specimen 115Figure 92 Cruciform test pieces 115Figure 93 Method of obtaining cruciform test specimen 116Figure 94 Tongue-bend test specimen 116Figure 95 Shear test piece 117Figure 96 Incompletely filled groove 118Figure 97 Undercut 118Figure 98 Lack of sidewall fusion 119Figure 99 Lack of root fusion 119Figure 100 Lack of inter-run fusion 119Figure 101 Incomplete root penetration 119


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Figure 102 Excess penetration bead 121Figure 103 Root concavity 121Figure 104 Shrinkage groove 121Figure 105 Drag 124Figure 106 Single-cantilever cutting machine 125Figure 107 Double-cantilever cutting machine 125Figure 108 Extended boom single-cantilever cutting machine 125Figure 109 Portal cutting machine 125Figure 110 Double-portal cutting machine 126Figure 111 Portal-cantilever cutting machine 126

List of tablesTable 1 Terms and symbols for main welding positions 69

Summary of pages

This document comprises a front cover, an inside front cover, pages ito viii, pages 1 to 142, an inside back cover and a back cover.


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Foreword

Publishing information

This part of BS 499 is published by BSI and came into effect on 31December 2008. It was prepared by Technical Committee WEE/1,Definition and symbols for welding. A list of organizationsrepresented on this committee can be obtained on request to itssecretary.

Supersession

This part of BS 499 supersedes BS 499-1:1991, which is withdrawn.

Relationship with other publications

This standard has been aligned, as far is as practicable, with existingEuropean and international lists of terms and definitions for welding,including BS EN 1792:2003, PD CEN/TR 14599, BS ISO 857 (all parts)and BS EN 13622. There might not be full agreement with standardsthat have not been adopted as British Standards. Where it was feltthat an existing definition needed clarification, this has been donewhile striving to not contradict the existing definition. As far aspracticable, the numbering system used in this standard follows thatof BS EN 1792:2003 with new numbers allocated to terms that are notin the European standard.

Where definitions are based on those in a European or internationalstandard, the identifier of the original standard is given in squarebrackets after the definition.

BS 499 is published in two parts, with a supplement to this part:

* Part 1: Glossary for welding, brazing and thermal cutting

* Part 1, Supplement: Definitions for electric welding equipment

* Part 2c: European arc welding symbols in chart form

NOTE 1 BS 499-1, Supplement is a reproduction of IEV 50 (851):1991.

NOTE 2 BS 499-2c is based on BS EN 22553.

Information about this document

This is a full revision of the standard, and introduces the followingprincipal changes:

Charts showing the derivation of welding, cutting and allied processesare given in Figure 1, Figure 2 and Figure 3.

Commonly used friction stir welding terms are included in the newSection 27.

Contractual and legal considerations

This publication does not purport to include all the necessaryprovisions of a contract. Users are responsible for its correctapplication.

Compliance with a British Standard cannot confer immunity fromlegal obligations.


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1 ScopeThis standard provides terms, symbols and definitions for welding,brazing and thermal cutting of metals. Some definitions might alsoapply to non-metals.

It does not cover mechanically fastened or adhesive bonded joints.

This standard is intended for designers, those drafting weldingspecifications, welding production, manufacturers and inspectionpersonnel.

Preferred and equivalent terms are given in bold type. Non-preferredterms are given in medium type. Deprecated terms are indicated assuch.


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Section 1. Terms common to more than one section

No. Term Definition

10 001 welding joining process in which two or more parts are unitedproducing a continuity in the nature of the workpiecematerial(s) by means of heat or pressure or both, and with orwithout the use of filler material

10 002 weld union of pieces of material resulting from welding

10 003 welder operator who performs or controls the welding process

10 004 welding operator person who controls fully mechanized or automatic fusionwelding processes

10 005 welding plantwelder: deprecated

apparatus for providing and controlling energy, andmovement if necessary, for making a weld

10 006 welding process particular method of welding involving the application ofcertain metallurgical, electrical, physical or mechanicalprinciples

10 007 manual welding welding where the electrode holder, welding hand gun, torchor blowpipe is manipulated by hand

10 008 partly mechanized welding manual welding where the wire feed is mechanized

10 010 mechanized welding welding in which the welding parameters are maintainedwithin a suitable tolerance by mechanical or electronic meansand which may be manually varied during the weldingprocess to create the required welding conditions

10 011 automatic welding welding in which all operations are preset and performedautomatically during the process

10 012 strength weld weld designed to withstand stress

10 013 parent metalbase metal: deprecated

metal to be joined or surfaced by welding, braze welding orbrazing (See Figure 4.)

10 014 filler metal welding consumable added during welding to form the weld

10 015 filler wirewelding wire

filler material in the form of a wire which may or may not be apart of the welding circuit

10 016 filler rodwelding rod: deprecated

filler material in the form of a rod which may or may not be apart of the welding circuit

10 017 flux material used during welding, brazing or braze welding toclean the surfaces of the joint chemically, to preventatmospheric oxidation and to reduce impurities

NOTE In arc welding, many other substances, which performspecial functions, are added.

10 018 deposited metal filler metal that has been added during welding

10 020 weld metal all metal melted during the making of a weld and retained inthe weld (See Figure 4.)

10 021 runpass

metal melted or deposited during one passage of anelectrode, or torch or blowpipe


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No. Term Definition

10 022 deposition rate mass of filler metal consumed per unit of productive weldingtime

10 023 weld zone zone containing the weld metal and the heat-affected zone(See Figure 4.)

10 024 heat-affected zoneHAZ

portion of non-melted parent metal whose microstructure hasbeen affected (See Figure 4.)

10 025 fusion zone part of the parent metal that is melted into the weld metal, asdetermined on the cross-section of a weld (See Figure 4.)

10 026 fusion line interface between the weld metal and the non-melted parentmetal as determined on the cross-section of a fusion weld

10 027 welding technique manner in which an operator manipulates an electrode, ablowpipe or a similar appliance

10 028 welding procedure specific course of action followed in welding, including a listof materials and, where necessary, tools to be used (SeeAnnex A to Annex G.)

10 030 (welding) sequence order and direction in which joints, welds or runs are made

10 031 weld run sequence order in which the runs of a weld or deposited layer areproduced

10 032 stud welding joining of a metal stud or similar part to a workpiece

NOTE Welding may be accomplished by arc, resistance, frictionor other suitable process, with or without external gas shielding.The weld is made over the whole end area of the stud orattachment.

10 033 hard facinghard surfacing

application of a hard, wear-resistant material to the surface ofa component by welding, braze welding or spraying

10 034 spatter globules of metal expelled during welding or cutting

Figure 4 Root, fusion penetration, weld junction and zones of typical welds

Key1 Weld zone2 Heat-affected zone3 Weld metal4 Parent metal5 Fusion penetration6 Weld junction7 Root (of weld)8 Fusion zone

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No. Term Definition

10 035 duty cycle 1) In the sense of welding operator duty cycle, ratio of timespent welding to the total time which includes otheractivities, e.g. changing electrodes, slag removal

2) In the sense of machine duty cycle, measure of thecapability of the welding equipment

10 036 transferred arc arc established between the electrode of the plasma arc torchand the workpiece

10 037 non-transferred arc arc established between the electrode and the constrictingnozzle of the plasma arc torch or thermal spraying gun

NOTE The workpiece does not form part of the electrical circuit.

10 038 electrode pick-up contamination of a non-consumable electrode by metal orscale from the surface of the workpiece

10 040 pick-up 1) In fusion welding, transfer of alloying elements from theparent metal to the weld metal as a result of dilution

2) In resistance welding, particles of the surface of theworkpiece that adhere to the surface of the electrodes, or viceversa

10 041 arc eye irritation of the eye caused by exposure to radiation from anelectric arc

10 042 electrode holder device to hold an electrode and to convey current to it

NOTE 1 In resistance welding, this is device holding a spotwelding electrode.

NOTE 2 In arc welding, this is a tool for clamping, guiding andconnecting a covered electrode to the welding circuit whileinsulating the operator from the welding

10 043 welding glassfilter glass

special filter that provides protection against glare whenwelding and in addition reduces the UV radiation and IRradiation that is dangerous to the human eye

10 044 heat filter colourless, transparent, heat-absorbing glass plate placedbetween the plain glass and the welding glass to protect theeyes

NOTE It is usually used in high current metal inert-gas welding.

10 045 blowpipetorch: deprecated

device for mixing and burning gases to produce a flame forwelding, brazing, braze welding, cutting, heating and similaroperations (See also terms 32 142 to 32 144.)

10 046 flashback retrogression of the flame beyond the blowpipe body into thehose, with possible subsequent explosion

10 047 pressure regulatorgas regulator

device for attachment to a gas cylinder or pipeline forreducing and regulating the gas pressure to the workingpressure required

10 048 residual welding stress stress remaining in a metal part or structure as a result ofwelding

10 050 pulse unidirectional flow of current of either polarity of briefduration

10 051 pulse time duration of a pulse


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No. Term Definition

10 052 welding primerweldable primer: deprecated

paint that is applied to a shot-blasted metal surface forprotective purposes, which does not have to be removed priorto welding and does not prevent the making of a satisfactoryweld

10 053 welding consumables all materials, such as filler materials, gas, flux or paste, used upduring welding and enabling or facilitating the formation ofa weld

10 054 welding equipment basic apparatus used in welding such as power source, as wellas wire feeder and powder feeder, etc.

10 055 welding accessories all items of welding equipment associated with welding,other than welding plant and welding consumables

10 056 layer stratum of weld metal consisting of one or more runs, side byside

10 057 building-up overlay welding to obtain or restore required dimensions

10 058 surfacing producing a layer of metal, by welding, on a workpiece toobtain desired properties or dimensions

10 060 joint preparationweld preparation

preparation for making a connection where the individualcomponents, suitably prepared and assembled, are joined bywelding or brazing

10 061 joint junction of workpieces or the edges of workpieces that are tobe joined or have been joined

10 063 air gapgap

1) In fusion welding, minimum distance at any cross-sectionbetween edges, ends or surfaces to be joined

2) In magnetically-impelled arc butt welding, space betweencomponent surfaces across which the arc is maintained duringthe heating (arcing) period

10 064 heat input heat introduced into the joint during welding, referred to acharacteristic dimension, such as a bead or weld length, weldcross-section, weld spot diameter

10 066 acceptance criteria specified quality criteria for defining conformance of a weld

10 067 acceptance level specific set of acceptance criteria where more than one setcan be selected

10 068 examiner person who has been appointed to verify compliance with theapplicable standard

NOTE In certain cases, an external independent examiner can berequired.

10 069 examining body organization that has been appointed to verify compliancewith the applicable standard

NOTE In certain cases, an external independent examining bodycan be required.

10 070 welding procedurespecificationWPS

document that has been qualified and provides the requiredvariables of the welding procedure to ensure repeatabilityduring production welding

10 071 welding procedurequalification recordWPQR

record comprising all necessary data needed for qualificationof a preliminary welding procedure specification

10 073 welding variable variable which influences the characteristics of the weldedjoint


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No. Term Definition

10 074 essential variable welding condition that requires qualification

10 075 additional variablenon-essential variable

welding condition addressed in the welding procedurespecification but not requiring qualification

10 076 standard material material produced and delivered in accordance with astandard or specification

10 080 re-start point on the run where the welding is or was re-started

10 081 post-weld heat treatment application of heat to an assembly after welding, brazing,soldering, thermal spraying or cutting

10 082 plasma gas ionized gas that generally forms the major portion of an arccolumn and provides a conducting path for the current

10 083 preheat heating of an appropriate area of a workpiece beforewelding, normally to achieve the preheating temperature

10 084 cooling rate rate of decrease of temperature with time over a specifiedtemperature range or time

10 085 heating rate rate of increase of temperature with time over a specifiedtemperature range or time

10 088 dissimilar material joint welded joint in which the parent materials have significantdifferences in mechanical properties and/or chemicalcomposition

10 089 as welded pertaining to the condition of weld metal, welded joints, andweldments after welding, but prior to any subsequentthermal, mechanical, or chemical treatments

NOTE For alloys that may undergo natural ageing (e.g. somealuminium alloys) the as-welded condition lasts only for a limitedperiod of time.

10 090 auxiliary material welding consumable used during welding, generally notforming part of the finished weld

10 091 quality level description of the qualities of a weld on the basis of type, sizeand amount of selected imperfections

10 092 fitness-for-purpose ability of a product, process or service to serve a definedpurpose under specific conditions

10 093 side edge of workpiece edge of workpiece, transverse to weld surface (see Figure 5,item 2)

NOTE Illustration from BS EN ISO 17659.


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Figure 5 Preparation for square butt weld

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1 Plate thickness 5 Upper workpiece surface

2 Side edge of workpiece 6 Reverse side

3 Gap 7 Plate edge

4 Joint length 8 Fusion face (unprepared)

Figure 6 Preparation for butt weld between plates with raised edges

2

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3

5

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Key

1 Plate thickness 5 Depth of raised edge

2 Length of raised edge 6 Radius of raised edge

3 Longitudinal side of raised edge 7 Fusion face (unprepared)

4 Abutment of raised edge


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No. Term Definition

10 094 abutment of raised edge contact surface of a raised-edge joint (see Figure 6, item 4)


10 095 homogeneous joint welded joint in which the weld metal and parent materialhave no significant differences in mechanical properties and/or chemical composition

NOTE A welded joint made of similar parent materials withoutfiller metal is considered homogeneous.

10 097 plate edge edge of a plate, normal to the joint axis (see Figure 5, item 7)


10 098 manufacturing organization workshop or site or both which is/are under the sametechnical and quality management

10 099 welding co-ordinator qualified person who has responsibilities in themanufacturing operation for carrying out one or more co-ordination tasks for welding or welding related matters, e.g.planning, controlling, supervising, monitoring, and whosecompetence and knowledge has been demonstrated bytraining, education and/or relevant manufacturing experience

10 100 high pressure blowpipe blowpipe in which the pressure of both the fuel gas and theoxygen/compressed air, measured immediately before thepoint of mixing, is higher than the pressure of the mixture,measured between point of mixing and welding nozzle

10 101 low pressure blowpipe blowpipe in which the fuel gas pressure, measuredimmediately before the mixing chamber, is lower than thepressure of the gas mixture, measured between the mixingchamber and welding nozzle

10 102 edge distance distance between the centre of a weld and the nearest edgeof the workpiece

10 103 range of qualification extent of qualification for an essential welding variable

10 104 batch sample one or more units of product selected at random from thebatch and considered to be representative of the batch

10 105 plate thickness See Figures 5, 6, 7, 8, 9, and 10.

NOTE Illustrations from BS EN ISO 17659.

10 106 nominal thickness specified thickness, excluding any permitted tolerances

10 108 welding procedure test making and testing of a representative welded joint, in orderto prove the feasibility of a welding procedure

NOTE 1 This term is not usually applied to any tests that mayhave been made during the development of a weldingprocedure.

NOTE 2 Sometimes an additional joint of a different type iswelded in order to obtain relevant test data.

10 109 function test test of a welding unit set-up in accordance with a weldingprocedure specification (WPS)

10 110 production test welding test carried out in the production environment onthe welding unit, on actual products or on simplified testpieces, during an interruption of normal production

10 111 pre-production welding test welding test having the same function as a welding proceduretest, but based on a non-standard test piece representative ofthe production conditions


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No. Term Definition

10 112 production sample testing testing of actual welded products sampled from a continuousproduction

10 113 manufacturers previouswelding experience

practice authenticated by test data demonstrating thatestablished production welding procedures have beencapable of consistently producing welds of acceptable qualityover a period of time

10 114 upper workpiece surface normally the side of the joint accessible for thecommencement of welding (see Figure 5, item 5, and Figure 7,item 5).


10 115 reverse side side of the joint opposite to the upper workpiece surface (seeFigure 5, item 6, and Figure 7, item 6).


Figure 7 Preparation for single bevel butt weld with backing

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Key

1 Plate thickness

2 Root gap

3 Depth of root face

4 Included angle

5 Upper workpiece surface

6 Reverse side

7 Fusion face (unprepared)

8 Fusion face (prepared)

9 Root face

10 Weld pool backing


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No. Term Definition

10 116 slope in welding geometry, angle between the root line and thepositive x-axis of the horizontal reference plane in straightwelds

10 117 ferrite number arbitrary number indicating magnetic attraction relative to aseries of reference samples and therefore proportional to theferro-magnetic phase content

10 118 work instruction simplified specification of the welding procedure, suitable fordirect application in the workshop

10 119 weld interface contact area after the welding force is applied

10 120 workpiece width width of the workpiece, parallel to the weld surface (seeFigure 8, item 2)


10 121 lap width dimension of overlap, transverse to the joint line (see Figure 9,item 4)


10 122 weld length overall length of continuous deposited weld metal in a joint


Figure 8 Configuration for double-covered lap joint

1

2

Key

1 Plate thickness 2 Workpiece width


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Figure 9 Configuration for single lapped joint

3

2

1

4

5

Key

1 Plate thickness

2 Side of lap face

3 Lap length

4 Lap width

5 Lapped area


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No. Term Definition

10 123 lap length length of lap, parallel to the joint line (see Figure 9, item 3)


10 124 joint length dimension of joint in the direction of the weld axis (seeFigure 5, item 4, Figure 63, item 3, and Figure 65, item 2)


10 125 batch collection of one or more units of products, made in a singleproduction run

10 126 parent material material to be joined, or surfaced, by welding, braze weldingor brazing

10 127 contracting parties parties who have entered into a supply contract

Figure 10 Preparation for single V-butt weld

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46143

5

10

Key

1 Plate thickness

2 Root gap

3 Depth of root face

4 Side edge of root face

5 Side edge of preparation

6 Width of preparation

7 Angle of bevel

8 Depth of preparation

9 Width of prepared face

10 Included angle

11 Fusion face (prepared)

12 Root face


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No. Term Definition

10 128 welding co-ordinationpersonnel

personnel who have responsibilities in the manufacturingoperation for welding and welding related activities whosecompetence and knowledge have been demonstrated by, e.g.training, education and/or relevant manufacturing experience

10 129 corrosion resistant surfacing adherent material for protection of a surface against corrosion

10 130 heat resistant surfacing adherent material for protection of a surface against heat

10 131 overlap in a lap joint, minimum distance between the edges ofoverlap platesin beam welding, portion of the weld pass remelted prior tothe slope downin seam welding, area in the preceding weld remelted by thesucceeding weld

10 132 rotation in welding geometry, angle between the centreline of a weldand the positive y-axis or a line parallel to the y-axis,measured in the counter-clockwise direction in the plane ofthe transverse cross-section of the weld

10 133 production welding welding carried out during manufacture before final deliveryto the end user

10 134 robotic welding automatic welding using a robot that can be preprogrammedto different welding paths and fabrication geometries

10 135 fully mechanized welding welding where all the main operations (excluding thehandling of the workpiece) are mechanized

NOTE Manual adjustment of welding variables during weldingis possible.

10 136 lapped area area of overlapped material in a lapped joint (see Figure 9,item 5)


10 137 preheat maintenancetemperature

minimum temperature in the weld zone which shall bemaintained if welding is interrupted

10 138 preheating temperature temperature immediately prior to the commencement ofwelding resulting from the heating of the parent metal in theregion of the weld

10 140 finishing welding welding carried out in order to remove casting defects andcore openings to ensure the agreed quality of castings

10 142 joint welding production welding used to join components together

10 143 qualified person person whose competence and knowledge have beenobtained by education, training and/or relevant experience

NOTE In order to demonstrate the level of competence andknowledge a qualification test may be required.

10 144 heterogeneous joint welded joint in which the weld metal and parent materialhave significant differences in mechanical properties and/orchemical composition

10 145 productive welding time time during which the welding operation takes place

10 146 welding conditions conditions under which welds are made; these includeenvironmental factors (e.g. weather), stress and ergonomicfactors (e.g. noise, heat, cramped working conditions) andworkpiece-related factors (e.g. parent metal, groove shape,working position)


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No. Term Definition

10 147 welding parameters information needed for the performance of welding with aspecified welding procedure

NOTE Welding parameters are, e.g. welding consumables,parent material, joint preparation, welding current, weldingvoltage, travel speed, preheating, working and interpasstemperature and run sequence.

10 148 welding sequence schedule schedule specifying the order and direction in which welds areto be made on a workpiece

10 149 welding time time required for making a weld (excluding preparatory orfinishing operations)

NOTE It consists of productive welding time and the servicingtime.

10 150 joint efficiency ratio of strength of a joint to the strength of the parentmetal, expressed as a percentage

10 151 faying surfaceinterface: deprecated

1) surface of one component that is intended to be in contactwith a surface of another component to form a joint2) in friction welding, contact area developed between theworkpieces after completion of the welding operation

10 152 stud fastener to be attached by stud welding

10 153 protrusion in stud welding, distance between the tip of the stud and theface of the support device in their initial position

10 154 lift in stud welding, distance between the stud tip and theworkpiece surface with the stud-lifting mechanism in positionand activated

10 155 semi-automatic weldingpartly mechanized welding

welding in which some of the welding parameters, such as arclength, are automatically controlled, but manual guidance isnecessary

10 156 shop weld weld made within the premises of the manufacturer of thewelded assembly

10 157 site weld weld made at the location where the assembly is to beinstalled

10 158 covered filler rodcoated filler rod: deprecated

filler rod having a covering of flux

10 159 fusion boundaryweld junctionfusion line

boundary between the fusion zone and the heat-affectedzone (See Figure 4.)

10 160 approved welding procedure documented welding procedure that has been approved bysuch means as an inspecting authority either by means of awelding procedure test or authentic documented experiencegained with the welding of joints similar to that to which thewelding procedure applies, or other approved methods

10 161 three-phase welding powersourcethree-phase welding machine

welding power source in which power is taken from all threephases of a three-phase supply to provide a single weldingcurrent or three single-phase welding currents

10 162 idling time time during which energy is available for welding but is notbeing used


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No. Term Definition

10 163 recovery time time required, after a change of conditions has occurred in awelding circuit, for either the current or the voltage, or both,to recover to a specific percentage of their value before thechange

10 164 cycle arbitrary unit of time, of duration equal to that of one cycle ofthe alternating current supply

NOTE Normally in the UK this is 1/50 s

10 165 nozzle-constricted arc arc that is constricted or shaped by the nozzle walls

10 166 vortex-constricted arc arc that is constricted by a vortex produced by swirling liquidor gas

10 167 transferred arc constricted arc that is struck between an electrode mountedwithin a torch and the workpiece

10 168 non-transferred arc constricted arc that is struck between an electrode within atorch and a second electrode which forms a nozzle throughwhich the plasma flows

10 169 partially transferred arc constricted arc formed when the workpiece is connected toone terminal of the power supply and the other terminal isconnected to an electrode within the torch; the torch nozzlealso forms part of the electrical circuit and is at anintermediate potential

10 170 sleeve joint joint where the ends of two pipes or round bars fit into ashort length of pipe, the inside diameter of whichapproximates to the outside diameter of the two othermembers

10 171 fixed shield independently mounted device to provide protection frominjury during welding or cutting

10 172 plain glasscover glass

clear glass or other transparent material used to protect thesurface of welding glass from spatter

10 173 welding spectacles spectacles fitted with welding glass, normally issued topersons whose duties require them to work in the vicinity ofwelding or cutting operations

10 174 welding goggles protective device enclosing a space in front of the eyes toshield them from injury during welding or cutting, fitted withwelding glass and plain glass

10 175 chipping goggles protective device enclosing a space in front of the eyes toshield them from injury during chipping, grinding or cutting,fitted with plain glass

10 176 face mask 1) protective device worn in front of the face to shield it frominjury during welding or cutting, fitted with welding glassand plain glass

2) protective device supplied with fresh air and worn over thenose and mouth

10 177 helmethead screenhead shield

protective device supported on the head and arranged toshield the face and throat from injury during welding, fittedwith a window consisting of welding glass and plain glass,and if necessary a heat filter

10 178 welding gloves gloves to protect the hands, or gauntlets to protect the handsand forearms, from heat and metal splashes due to welding orcutting


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No. Term Definition

10 179 open injector-mixerbunsen-type mixer

injector-mixer where the additional gas is drawn in from theatmosphere

10 180 closed injector- mixer injector-mixer that is closed to the atmosphere, the entrainedgas being drawn up through a tube connected to the unit

10 181 cone more luminous part of a flame, which is adjacent to thenozzle orifice

10 182 feather carbon-rich zone, visible in a flame, extending around andbeyond the cone when there is an excess of carbonaceous gas

10 183 gas envelope gas surrounding the inner cone of an oxy-fuel gas flame

10 184 threaded hose connection threaded part (inlet or outlet) of a welding or cuttingappliance to which a fitted hose is coupled

NOTE Threaded hose connections, hose coupling nuts and hosecouplers have right-hand threads for non-combustible gases andleft-hand threads for combustible gases. Hose coupling nuts andhose couplers having left-hand threads are notched.

10 185 hose coupling nutunion nut: deprecated

nut used for securing the hose coupling nipple to a threadedhose connection or to a hose coupler (See note to term10 184.)

10 186 hose coupling nipple metal component, one end of which is inserted into a hose,the other end has a seating and a shoulder around which canbe rotated the hose coupling nut (See note to term 10 184.)

10 187 fitted hose length of hose at each end of which is a hose coupling nippleand a hose coupling nut

10 188 hose coupler component, consisting of a hexagonal centre portion withthreaded ends, for connecting two lengths of fitted hose(See note to term 10 184.)

10 189 flame snap-out unintentional extinction of the flame outside the nozzleorifice

10 190 gas economizer auxiliary device designed for temporarily cutting off thesupply of gas to the welding equipment, except the supply toa pilot jet where fitted

10 191 two-stage regulator gas regulator in which the gas pressure is reduced to theworking pressure in two stages

10 192 manifold regulatormulti-stage regulator

gas regulator in which the gas pressure is reduced to theworking pressure in more than one stage

10 193 flame arrestorflashback arrester

safety device fitted in a fuel gas system to prevent anyflashback reaching the fuel gas pipeline or supply

10 194 hydraulic back pressure valve water-charged non-return safety valve fitted in an acetylenegas system to prevent flashback or back pressure from theblowpipe reaching the acetylene generator

10 195 flame normalizing normalizing carried out by direct flame heating

10 196 interpulse time period of time between successive pulses during the makingof a single weld

10 197 welding cyclewelding cycle time

period required to complete a welding cycle

10 198 weld timer device that controls only the weld time


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No. Term Definition

10 199 welding rectifierwelding convertorrectifier converter

device that converts single or multiphase power from thefrequency of the power supply to unidirectional current

10 200 stored-energy welding method of welding in which the welding energy is stored inan inductor, a capacitor, an electric accumulator or a flywheelduring a period of time relatively long compared to thewelding time

10 201 burnt weld weld in which the weld metal has been grossly overheatedcausing excessive oxidizing thereby reducing the strength ofthe joint

10 202 weldability ease with which a material or materials can be welded to givean acceptable joint

10 203 plasma arc transferred arc in which a constriction (mechanical ormagnetic) is used to produce a thin pencil-like configurationof plasma and electrons to give a high heat concentrationover a small area

10 204 plasma jet jet or plasma formed by a non-transferred arc and expelledthrough an orifice at high velocity by gas pressure

10 205 plasma weld surfacing surfacing or cladding in which the heat is provided by aplasma arc that may be transferred or partially transferred tothe workpiece

NOTE The cladding material may be applied as powder or asfiller wire that is fused to the parent metal.

10 206 nozzletip: deprecated

generally detachable part of a blowpipe from which gas orgases emerge

10 207 blowpipe head part of a blowpipe to which a nozzle is fitted

10 208 blowpipe shank part of a blowpipe that is normally held or gripped, to whichare fixed the valves and threaded hose connections

10 209 combined blowpipecombined outfit: deprecatedcombined set: deprecated

blowpipe that, when fitted with the appropriate attachments,can be used for welding, cutting, heating or flame cleaning

10 210 head mixing blowpipe blowpipe with a mixer or injector-mixer in the head

10 211 harsh flame flame in which the velocity of the gases is higher than normal

10 212 soft flame flame in which the velocity of the gases is lower than normal

10 213 dissolved acetylene acetylene made stable under pressure by being dissolved in aliquid, e.g. acetone

10 214 groove weld weld in a preparation made to receive weld metal

10 215 roll welding welding with pressure in which a force is progressively appliedby mechanically operated rolls after heating by differentmeans

10 216 robot programmable, multi-function manipulator

10 217 manipulation operation of grasping and moving an object

10 218 adaptive control systemfeedback control system

control method in which control parameters are continuouslyand automatically adjusted in response to measured processvariables to achieve the specified performance


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No. Term Definition

10 219 joint recognition form of adaptive control that recognizes variations in thegeometry detects changes in the joint geometry and instructsthe welding machine to take the appropriate correctiveaction

10 220 weld recognitionweld feature recognition

form of adaptive control that recognizes variations in thegeometry (including penetration depth) of the weld or weldpool being made and instructs the welding machine to takethe appropriate corrective action

10 221 joint trackingseam tracking

form of adaptive control that monitors changes in thelocation of the joint to be welded and instructs the weldingmachine to take the appropriate corrective action

10 222 forehand welding welding technique in which the welding torch or gun ispointed in the direction of welding

10 223 backhand welding welding technique in which the welding torch or gun ispointed towards the completed weld, i.e. opposite to thedirection of welding


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Section 2. Terms relating to welding with pressure

Subsection 21. Terms relating to more than onesubsectionNo. Term Definition

21 001 welding with pressure welding in which sufficient outer force is applied to causemore or less plastic deformation of both the faying surfaces,generally without the addition of filler metal

NOTE Usually, but not necessarily, the faying surfaces areheated in order to permit or to facilitate unifying.

21 002 interface contact area when the welding force is applied

21 003 HF induction welding welding in which an alternating electric current of at least10 kHz is induced in the work to produce heat which inassociation with a forging action produces a joint

21 004 upset metalupset

parent metal proud of the normal surfaces of the work as aresult of forging or pressing

21 005 upset allowance length allowed for the total shortening of both componentsdue to upsetting

21 006 upset speed rate of movement of the moving workpiece during upsetting

21 007 welding cycle succession of operations effected by the machine for themaking of a weld and the return to the initial position

21 008 upset force1) force producing or tending to produce upset metal

21 010 upset pressure pressure (force per unit area) resulting from the upset force

21 011 total allowance In pressure, resistance butt, flash or friction welding, thelength allowed, in preparation for welding, for the totalshortening of both components due to all the operations thatare actually used in the making of a weld

21 012 upset length total actual shortening of both components due to theforging action in the making of a weld

21 013 forging forceforge force

1) force applied normal to the faying surfaces to complete theweld2) In friction welding, force applied normal to the fayingsurfaces at the time when relative movement between thecomponents is ceasing or has ceased

21 015 forging timeforge time

duration of application of the forging force

21 016 dwell in resistance welding, maintain the electrode force after thecessation of current

21 017 dwell time in fusion welding, time during which the energy sourcepauses at any point in each oscillation

21 020 oxy-fuel gas pressurewelding

welding with pressure in which the workpieces are heated atthe faying surfaces by an oxy-fuel gas flame and the weld ismade by applying a force without addition of filler metal; theassembly may be of the open or closed type

NOTE This process is illustrated in Figure 11.

1) Force is sometimes incorrectly referred to as pressure. See terms 21 013 to 21 020.


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No. Term Definition

21 021 ultrasonic welding welding process in which mechanical vibrations of lowamplitude superimposed on a static force, and usually atfrequencies above the audible limit, make a weld betweentwo surfaces to be joined at a temperature well below themelting point of the parent metal

NOTE Additional heat may or may not be applied.

21 022 diffusion welding welding with pressure whereby the workpieces are kept incontact under specified continual pressure and are heatedeither on their faying surfaces, or in their entirety at a definedtemperature over a controlled time (accompanied by a figure)

NOTE This results in local plastic deformation and therebyintimate contact of the surfaces and diffusion of the atomsthrough the interface. This produces complete continuity of thematerial. The operation may take place in a vacuum, under a gasshield or in a fluid, preferably without the addition of a fillermetal.

21 023 explosive cladding cladding by explosive welding (see 26 001)

21 024 magnetically-impelledarc butt welding

welding process in which the faying surfaces of theworkpieces are heated by a short duration arc between themand then brought together by the application of a force, thearc being impelled along the joint line by magnetic fields

NOTE The arc current can be either constant or increased insteps.

21 025 upsetting 1) operation of locally increasing the cross-sectional area of aworkpiece by the application of a longitudinal force2) final operation of butt or flash welding comprising theapplication of a force to the ends of the workpieces afterheating to welding temperature

Figure 11 Oxy-fuel gas pressure welding

34

5

12

a) Closed assembly b) Opened assembly

Key

1 Upset

2 Weld

3 Welding blowpipe

4 Gas flame

5 Workpiece


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No. Term Definition

21 026 pressure contact area initial surface contact area of the components through whichforce is transmitted

21 027 forward force2) force applied to the movable head of a welding machine inthe direction necessary to make a weld

21 028 initial force2) first steady or peak force applied normal to the interface,during the welding cycle

21 029 welding force2)

welding load: deprecatedforce, at the abutting surfaces of a workpiece, used to make aweld

21 030 post-weld upset force2) force required to reduce the workpiece to its correct lengthafter welding

21 031 post-heating force2) force applied by the electrodes to the work during the timepost-heating current is flowing

21 032 forward pressure pressure (force per unit area) resulting from the forward force

21 033 initial pressure pressure (force per unit area) resulting from the initial force

21 034 welding pressure pressure (force per unit area) resulting from the welding force

21 035 post-weld upset pressure pressure (force per unit area) resulting from the post-weldupset force

21 036 post-heating pressure pressure (force per unit area) resulting from the post-heatingforce

21 037 overhang distance a component projects from the die or clamp in thedirection of the mating component for resistance butt, flash,friction, pressure or magnetically impelled arc butt welding

21 038 digital timer apparatus for controlling intervals of time by means ofcounting, to a preset number, pulses which have a constantrate of repetition

21 039 analogue timer apparatus for controlling intervals of time that relies uponany time dependent physical change

21 040 sequence timer apparatus comprising a group of timers for controllingvarious functions in a welding cycle in a predeterminedsequence

21 041 total loss In pressure, resistance butt, flash, friction or magneticallyimpelled arc butt welding, total amount of shortening ofboth components due to all the operations that are actuallyused in the making of a weld

21 042 forge weldingfire welding

welding with pressure in which the workpieces are heated inair in a forge and the weld is made by applying blows or someother impulsive force sufficient to cause permanentdeformation at the interfaces

2) Force is sometimes incorrectly referred to as pressure. See terms 21 032 to 21 036.


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Subsection 22. Terms relating only to resistance welding

No. Term Definition

22 001 resistance welding welding with pressure in which the heat necessary forwelding is produced by resistance to an electrical currentflowing through the welding zone

22 002 resistance butt weldingslow butt welding:deprecatedupset butt welding:deprecated

resistance welding in which the components are buttedtogether under pressure, and current is allowed to flow untilthe temperature is reached at which upset metal is producedand the weld is completed

22 003 flash weldingflash butt welding:deprecated

resistance welding during which heating is obtained whenthe workpieces are progressively and repeatedly advancedtowards each other, causing the current to flow throughlocalized points, thus creating flashing and expulsion ofmolten metal

22 004 spot welding resistance welding in which a weld is produced at a spot in thework-piece between electrodes, the weld being ofapproximately the same area as the electrode tips, or as thesmaller of tips of differing size; force is applied to the spot,usually through the electrodes, continuously throughout theprocess

22 005 stitch welding spot welding in which successive welds overlap

22 006 multiple spot welding spot welding in which, by the use of more than twoelectrodes, two or more welds are made simultaneously or inan automatically controlled sequence

22 007 series spot welding spot welding in which two or more welds are madesimultaneously in electrical series (See Figure 12.)

Figure 12 Examples of series spot welding


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No. Term Definition

22 008 seam welding resistance welding in which force is applied continuously andcurrent continuously or intermittently to produce a linearweld, the workpiece being between two electrode wheels orbetween an electrode wheel and an electrode bar; the wheelsapply the force and current and rotate continuously duringthe making of the linear weld

22 010 projection welding resistance welding in which the force and current arelocalized by the use of a projection or projections raised on orformed from one or more of the faying surfaces, theprojections collapsing during welding

22 011 resistance stud welding stud welding using projection welding(See terms 10 032 and 22 010)

22 012 percussion welding welding with pressure employing the heat from an arcproduced by a rapid discharge of electrical energy; pressure isapplied percussively during or immediately following theelectrical discharge

22 013 HF resistance welding resistance welding in which an alternating electric current ofat least 10 kHz is fed through contacts to the work to providethe heat for welding; the high frequency current concentratesalong adjacent surfaces to produce highly localized heat priorto the application of welding force

22 014 cross-wire weld resistance weld at the point of contact between crossed wiresor rods made with pressure applied continuously

22 015 resistance welding electrodeelectrode

replaceable portion of a resistance welding machine thattransmits current and applies force to the pieces to be welded

22 016 electrode shank portion of an electrode for spot or stitch welding intended tobe held by, and to make electrical contact with, an electrodeholder

22 017 electrode wheel seam welding electrode in the form of a rotating disc

22 018 flashing allowance length allowed for the total shortening of both componentsdue to flashing, in preparation for flash welding

22 020 electrode pressure pressure (force per unit of electrode contact area) resultingfrom the electrode force

22 021 flashing time3) In flash welding, period of time between the start ofcontinuous flashing and the time when the upset force isapplied

22 022 upset time3) duration of upset travel

22 023 upset current time3) time during which upset current flows

22 024 cool time3)

off-timeIn pulsation and seam welding, period of time between twosuccessive heat times in the same welding cycle

22 025 weld time3) In resistance welding, duration of continuous flow of weldingcurrent

22 026 hold time3)

dwell timeperiod of time between the cessation of current in a weldingcycle and the cessation of electrode force

22 027 welding current current (excluding preheating current) used to bring theworkpiece to, and maintain it at, welding temperature

3) Attention is drawn to Figures 14 to 25 for diagrammatic representation of these terms.


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No. Term Definition

22 028 flashing current current flowing during flashing time

22 030 flashing travel distance travelled by the moving head during flashing

22 031 flashing speed rate of travel of the moving head during flashing

22 032 throat depththroat

in resistance welding, usable distance from the centre of theplatens or the axes of the electrodes or, in the case of obliqueelectrodes, the point of intersection of the electrode axes inthe working position or the contact line of electrode wheelsand that part of the equipment body located closest to it

22 033 throat gap 1) in spot and seam welding equipment, usable distancebetween the arms or the outer current-conducting parts ofthe welding circuit2) in projection welding equipment, clamping distancebetween the platens

22 034 indirect spot welding spot welding in which only one electrode tip is used per weld;a backing electrode or the workpiece itself completes theelectrical circuit and resists the force of the electrode tip

22 035 forge delay time period of time between the start of weld time and the instantof application of maximum welding force

22 036 backing electrode plate or strip of current-carrying material used in place of anelectrode on one side of the work to reduce the marking formulti spot, seam or projection welds

22 037 upset current current flowing during upsetting

22 038 flashing loss In flash welding, total actual shortening of both componentsduring the flashing time

22 040 flashing in flash welding, phenomenon occurring as the componentsare progressively advanced towards each other, when thecurrent, confined to localized points of contact, causesrepeated expulsion of molten metal

22 041 double-conductor connectioncable

cable comprising two conductors providing an electrical linkbetween the secondary terminals of a resistance weldingtransformer and the welding set, and designed to have as lowan electrical resistance as possible

22 042 single-conductor connectioncable

cable comprising one conductor providing an electrical linkbetween the secondary terminals of a resistance weldingtransformer and the welding set

22 043 staggered resistance welds generally spot welds in two or more rows, in a staggeredpattern (see Figure 14)

22 044 projection diameter maximum diameter of individual projection [See Figure 13a),item 4]



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No. Term Definition

22 045 annular projection diameter mean diameter of an annular projection [See Figure 13c),item 8]


22 046 nugget diameter in resistance spot and projection welding, mean of theminimum and maximum diameters of the fused zonemeasured at the interface omitting the corona bond area

22 047 row pitch perpendicular distance between rows of spot welds, alignedparallel to the joint axis (see Figure 14, item 4)


Figure 13 Forms of projection welds

13

4

2

5

5

5

5

2 6

7

3

a) Round projections b) Elongated projections

3

7

85

5

2

c) Annular projections

Key

1 Plate thickness

2 Pitch (of projections)

3 Projection height

4 Projection diameter

5 Edge distance

6 Projection length

7 Projection width

8 Annular projection diameter


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Figure 14 Typical example of weld made using pressure Double row of staggered, spaced spot welds

1 5

5

4

2

3

Key

1 Weld length

2 Weld pitch

3 Stagger

4 Row pitch

5 Edge distance

Figure 15 Typical example of weld made using pressure Projection weld

1

3

2

Key

1 Weld nugget

2 Nugget diameter

3 Nugget thickness


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No. Term Definition

22 048 pitch of projections distance between adjacent projection centres in a directionparallel to the joint line [see Figure 13a), item 2, Figure 13b),item 2, and Figure 13c), item 2].


22 049 weld pitch In a double row of spot welds, distance between adjacentweld centres in a direction parallel to the joint line (same asstagger; see Figure 14, item 2)


22 050 foil thickness thickness of foil in a foil butt seam weld (see Figure 16, item 3)


22 051 nugget thickness maximum height of nugget in the thickness direction (seeFigure 15, item 3)


22 052 projection height height of projection prior to welding [see Figure 13a), item 3,Figure 13b), item 3, and Figure 13c), item 3]


22 053 indentation depression on the exterior surface or surfaces of a spot orseam weld

22 054 projection width In elongated projections, width of projection, transverse tothe joint direction [see Figure 13b), item 7]In annular projections, difference between the inner andouter radius of an annular projection [see Figure 13c), item 7]


22 055 foil width width of foil, measured transverse to the joint axis (seeFigure 16, item 2)


Figure 16 Foil butt-seam weld

3

4

2

4

1

Key

1 Foil length

2 Foil width

3 Foil thickness

4 Foil contact surface


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No. Term Definition

22 056 projection length length of an elongated projection [see Figure 13b), item 6]


22 057 foil length length of foil, parallel to the joint axis (see Figure 16, item 1)


22 058 weld nugget zone in a spot, seam or projection weld where the metal hasbeen melted (see Figure 17)

No. Term Definition

22 059 indentation depth depth of permanent indentation of joint surface produced byelectrode after welding (see Figure 18, item 5)


22 060 nugget overlap width of re-melting of nugget by adjacent nugget (see Figure19, item 3)


Figure 17 Weld nugget

Figure 18 Typical example of weld made using pressure Resistance spot welds

4

2

1

3

5

Key

1 Weld nugget

2 Nugget diameter

3 Nugget thickness

4 Indentation

5 Indentation depth


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No. Term Definition

22 061 resistance weld setter in resistance welding, person who sets up mechanized orautomatic welding

22 062 foil contact surface contact surface between foil and workpiece (see Figure 16,item 4)


22 063 mash seam weld seam or stitch weld, between two components of similarthickness, where the amount of overlap determines the widthof weld, so made that the ultimate thickness of the workpieceat the weld approximates to that of one component (seeFigure 20)

22 064 nail head welding variant of heated nozzle welding in which the end of one ortwo wires which has been fed through the nozzle and heatedby a flame or electric discharge, forms a small globule, whichunder the effect of the applied force is flattened into theshape of a nail head (see Figure 21)

Figure 19 Typical example of weld made using pressure Seam weld

2

13Key

1 Nugget diameter

2 Weld length

3 Nugget overlap

Figure 20 Mash weld


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No. Term Definition

22 065 straight flash welding flash welding technique in which flashing starts as soon as theworkpieces are brought into contact and is maintained untilupsetting takes place

22 066 flash welding with preheating flash welding technique in which preheating current isapplied to the workpieces to facilitate the onset of flashing

22 067 roller spot welding spot welding in which force is applied continuously andcurrent intermittently to produce a line of separate spotwelds, the workpieces being between two electrode wheelsor between an electrode wheel and an electrode bar; thewheels apply the force and current and rotate continuouslywhile the line of welds is being made

22 068 step-by-step roller spotwelding

spot welding in which force is applied continuously andcurrent intermittently to produce a line of separate spotwelds, the workpieces being between two electrode wheelsor between an electrode wheel and an electrode bar; thewheels apply the force and current and are stationary duringthe normal flow of current and rotate when reduced or nocurrent is flowing

22 069 step-by-step seam welding resistance welding in which force is applied continuously andcurrent intermittently to produce a linear weld, theworkpiece being between two electrode wheels or betweenan electrode wheel and an electrode bar; the wheels applythe force and current and are stationary during the normalflow of current and rotate when reduced or no current isflowing

Figure 21 Nail head welding

1

2

6

5

4

3

Key

1 Flame

2 Molten metal globule

3 Power source

4 Nozzle

5 Workpiece

6 Weld


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No. Term Definition

22 070 step-by-step welding seam or roller spot welding in which the electrode wheel isstationary during the passage of weld current and rotateswhen reduced or no current is flowing

22 071 butt-seam welding resistance welding applied progressively to a butt joint;electrodes press on the work on each side of the joint to passcurrent through it while welding force is generally applied byother means

22 072 foil butt-seam weldingtape butt-seam welding

seam welding of two close square butted components withmetal tape or wire placed or fed centrally to bridge one orboth sides of the joint (see Figure 16)

22 073 pulsation weldingwoodpecker welding:deprecated

spot or projection welding in which the welding current isinterrupted one or more times without release of pressure orchange of location of the electrodes

22 074 half-cycle welding spot, projection or percussion welding in which the weldingoperation is completed in a whole or part of any one halfcycle of the a.c. supply

22 075 electrode tip surface of an electrode for spot or stitch welding intended tomake contact with the workpiece

22 076 vertical electrode electrode for spot or stitch welding in which the electrode tipis normal to the axis of the electrode shank

22 077 angle electrodeinclined electrode

electrode for spot or stitch welding in which the electrode tipis not normal to the axis of the electrode shank

22 078 offset electrode electrode for spot or stitch welding in which the electrode tipis not concentric with the axis of the electrode shank

22 079 vertical centre electrodestraight electrode

vertical electrode where the electrode tip is concentric withthe axis of the electrode shank (See Figure 22.)

22 080 vertical offset electrode vertical electrode where the electrode tip is not concentricwith the axis of the electrode shank (See Figure 23.)

No. Term Definition

22 081 angle offset electrode angle electrode in which the electrode tip is not concentricwith the axis of the electrode shank (see Figure 24)

22 082 cranked offset electrodecranked electrode

offset electrode in which the centreline of the electrode is notstraight (see Figure 25)

Figure 22 Vertical centre electrode Figure 23 Vertical offset electrode


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No. Term Definition

22 083 pad electrodeflat electrode

electrode having an area of contact with the work that ismuch larger than the weld required

22 084 tread peripheral surface of an electrode wheel

22 085 electrode pick-up contamination of the resistance welding electrode by metalor scale from the surface of the workpiece

22 086 surface pick-up contamination of the surface of a resistance weld by particlesof the electrode

22 087 welding diedie

device for locating the components of a workpiece in aresistance welding machine and for transmitting force andwelding current to them

22 088 insert small piece of metal, usually hard wearing and ofcomparatively high resistivity, used as an electrode tip, orattached to a welding die and projecting sufficiently beyondit to make contact with the workpiece

22 089 platen part of a resistance welding machine on which welding diesor bolsters can be mounted and which conveys force andwelding current to them

22 090 bolster electrode holder for mounting on a platen

22 091 arm member projecting from a resistance welding machine, whichcarries current, or supports a conductor carrying current, to anelectrode holder and which is required to transmit or supportthe welding force

22 092 fin extrusion of metal extending outward beyond the upsetmetal in the form of a fin

22 093 splash thin streaks of metal left adhering between the componentsor on their surfaces as the result of molten metal beingexpelled from a joint or from under the electrodes duringspot, seam, or projection welding

Figure 24 Angle offset electrode Figure 25 Cranked offset electrode


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No. Term Definition

22 094 weld contact areainterface: deprecated

area through which welding current passes from onecomponent to another during resistance welding

22 095 electrode contact areaclamp contact areadie contact area

area through which current passes from an electrode or aclamp to the workpiece

22 096 backward force4)

back pressure: deprecatedforce tending to separate the electrodes

22 097 electrode force4) force transmitted by the electrodes to the workpiece

22 098 backward pressureback pressure: deprecated

pressure (force per unit area) resulting from the backwardforce

22 099 hand-operated weldingmachine

welding machine in which the mechanical force is applied byhand

22 100 foot-operated weldingmachinepedal-operated weldingmachine

welding machine in which the mechanical force is applied bymeans of a pedal

22 101 power-operated weldingmachine

welding machine in which mechanical force is applied by aninanimate source of power

22 102 motor-operated weldingmachine

welding machine in which the travel of the electrode isprovided and the mechanical force is applied by means of amotor-driven mechanism

22 103 portable spot-weldingmachine

spot-welding machine:

a) that can be carried about complete, or

b) in which the electrodes, the moving arms and the forceapplication device have flexible connections to a fixedtransformer and control equipment, thus providing a limitedamount of portability

22 104 plier spot-welding machinepincer spot-welding machine

portable spot-welding machine in which force is applied toelectrodes by means of a lever system similar to that of pliers

22 105 capacitor spot-weldingmachine5)

condenser-dischargespot-welding machine

spot-welding machine in which welding current is caused toflow through the secondary winding of a transformer and thewelding electrodes by the discharging of a capacitor throughthe primary winding of the transformer

22 106 inductor spot-weldingmachine5)

induction spot-weldingmachine

spot-welding machine in which the welding current is causedto flow through the secondary winding of the transformerand the welding electrodes by the interruption of the flow ofa direct current through the primary winding of thetransformer

22 107 battery spot-weldingmachine5)

spot-welding machine in which a battery is used to providethe welding current

22 108 weld slug piece of metal pulled from one sheet when a spot orprojection weld is prised apart

NOTE The diameter of the slug may be used for weld qualityassessment.

4) Force is sometimes incorrectly referred to as pressure. See terms 22 020 and 22 098.5) These machines are sometimes referred to as stored-energy machines.


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No. Term Definition

22 109 preheat time duration of preheating current

NOTE In flash welding it is the time between the first passage ofcurrent and the start of continuous flashing.

22 110 squeeze time6) period of time between the normal application of force bythe electrodes to the work and the first passage of current

22 111 heat time6)

on-timeduration of each successive current impulse, in pulsation andseam welding

22 112 step time6) In roller spot welding and in step-by-step roller spot welding,period of time between successive weld times

22 113 chill time6)

quench timeperiod of time between the end of welding current and thestart of post-heating current

22 114 post-heat time6) duration of flow of post-heating current

22 115 current-off time6) period of time between the cessation of current in onewelding cycle and the beginning of current in the next

22 116 pressure-off time6) In spot, seam and projection welding, period of time betweentwo successive welding cycles when no electrode force isbeing applied to the workpiece

22 117 preheating current current used to raise the temperature of a workpiece fromambient temperature to a predetermined value belowwelding temperature just before the application of weldingor flashing current

6) Attention is drawn to Figures 26 to 37 for diagrammatic representations of these terms.


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Figure 26 Time and pressure diagram for simple spot, stitch, or projection welding

Figure 27 Time and pressure diagram for pulsation spot or projection welding

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.35


Figure 28 Time and pressure diagram for spot or projection welding, programme control

Figure 29 Time and pressure diagram for pulsation spot or projection welding, programme control

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STANDARD

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Figure 30 Time and pressure diagram for spot welding, programme control with dual-pressure cycle

Figure 31 Time and pressure diagram for seam welding

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STANDARD

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.37


Figure 32 Time and pressure diagram for step-by-step seam welding

Figure 33 Time and pressure diagram for roller spot welding

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STANDARD

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Figure 34 Time and pressure diagram for step-by-step roller spot welding

Figure 35 Time and platen movement diagram for straight flash welding

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.39


Figure 36 Generalized diagram of speed, applied force, axial movement and time for continuous drive friction welding

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STANDARD

40

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Figure 36 Generalized diagram of speed, applied force, axial movement and time for continuous drive friction welding (concluded)

BS499-1:2009

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STANDARD

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.41


Figure 37 Generalized diagram of speed, applied force and axial movement with time for stored energy friction welding

BS499-1:2009

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STANDARD

42

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No. Term Definition

22 118 post-heating current current that is passed through a completed weld to heat it,usually for metallurgical reasons

22 119 dual-pressure cycle welding cycle characterized by the application of twodifferent predetermined electrode forces

22 120 programme control method of controlling a predetermined sequence of changesof current and/or force during a welding cycle

22 121 heat control means of smoothly controlling the value of the currentflowing through a resistance welding machine

22 122 constant current control electronic control of the value of welding current, to make itspreset value constant and independent of variations in eithermains voltage or the amount of magnetic material introducedinto the throat of the welding machine

22 123 synchronous control electronic control system that ensures that the instant ofclosing the circuit to a resistance welding transformer isalways at a preset electrical angle to the instant of zerovoltage of the a.c. supply

22 124 non-synchronous control control system that does not ensure that the instant of closingthe circuit to a resistance welding transformer is repetitivelyat the same instantaneous voltage of the a.c. supply

22 125 phase shift alteration of the phase relationship between two a.c. voltages

NOTE Generally this is used to control the period of conductionin each half cycle of ignitron or thyristor contactors.

22 126 phase anglefiring angle

electrical angle between the instantaneous zero voltageapplied to the anode of an ignitron or thyristor and the pointat which it conducts in each half cycle

22 127 slope control control of the rate of rise or decay of current and the timeduring which either takes place in the power circuit of aresistance welding machine

NOTE This should not be confused with term 32 129.

22 128 rate of slope rate of change of current when using slope control

22 129 slope time duration of slope-up or slope-down

22 130 upset travel

bs 499-2009. welding symbol

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